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Quality in Any Language™
© 2008 Roberts-Gordon LLC
ROBERTS GORDON
UltraVac
Infrared Heating
Installation Manual
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Roberts-Gordon LLC
1250 William Street
P.O. Box 44
Buffalo, New York 14240-0044
Telephone: 716.852.4400
Fax: 716.852.0854
Toll Free: 800.828.7450
www.rg-inc.com
®
Controls for
Modulating
CORAYVAC
Systems
Owner
P/N 10081601NA Rev F 10/08
™
®
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Summary of Contents for Roberts Gorden UltraVac NEMA 4
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Page 1: Installation Manual
Quality in Any Language™ © 2008 Roberts-Gordon LLC ROBERTS GORDON UltraVac Controls for Modulating CORAYVAC Infrared Heating Installation Manual Installer Please take the time to read and understand these instructions prior to any installation. Installer must give a copy of this manual to the owner. Owner Keep this manual in a safe place in order to provide your serviceman with necessary information. -
Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1: Introduction... 1 1.1 What is ROBERTS GORDON 1.2 CORAYVAC ® Design Requirements... 1 1.3 General Requirements ... 1 1.4 Check Installation Materials ... 1 1.5 Carton Contents ... 2 1.6 Safety ... 5 1.7 Example Site Layout... 5 SECTION 2: Specifications ... - Page 5 TABLE OF FIGURES Figure 1: Example Site Layout ... 6 Figure 2: ROBERTS GORDON ® ULTRAVAC™ Controller Specifications ... 8 Figure 3: Variable Frequency Drive Components (Factory pre-wiring shown) ... 10 Figure 4: Controller Mounting... 11 Figure 5: Indoor Sensor Cable Detail ... 12 Figure 6: Outdoor Sensor, VFD (0-10 V) Signal, RS-485 Communications Cable and Pressure Switch Cable Detail...
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Page 7: Section 1: Introduction
SECTION 1: INTRODUCTION 1.1 What is ROBERTS GORDON The ROBERTS GORDON ® ULTRAVAC™ is a micro- processor based control package designed for modulating control of CORAYVAC outdoor temperatures. This controller is capable of giving control outputs to one vacuum pump and three heating zones. The controller also features inputs which are used for indoor and outdoor signal condition monitoring. -
Page 8: Carton Contents
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER 1.5 Carton Contents URVSC: ULTRAVAC™ Satellite Controller ULTRAVAC™ Controller Low Voltage 24 V Wiring ULTRAVAC™ Installation Manual (P/N 10081601NA) URVCCL: ULTRAVAC™ Central Controller with TCP/IP Communication Module Low Voltage 24 V Wiring NC C NC C ULTRAVAC™... - Page 9 URVCCM: ULTRAVAC™ Central Controller with Modem Low Voltage 24 V Wiring NC C NC C NC C NC C NC C NC C ULTRAVAC™ Controller with Modem Installed ULTRAVAC™ Software (P/N 10080421) ULTRAVAC™ Software Manual (P/N 10081600NA) ULTRAVAC™ Installation Manual (P/N 10081601NA) Comms Equalization Cable (P/N 10080450) Line Voltage 120 V Wiring...
- Page 10 ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER URVCCR: ULTRAVAC™ Central Controller with RS-485 Converter Low Voltage 24 V Wiring NC C NC C ULTRAVAC™ Controller with Modem Installed ULTRAVAC™ Software (P/N 10080421) ULTRAVAC™ Software Manual (P/N 10081600NA) ULTRAVAC™ Installation Manual (P/N 10081601NA) Comms Equalization Cable (P/N 10080450) RS-485 Converter Package (P/N 10080430)
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Page 11: Safety
1.6 Safety Your Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special atten- tion when reading and following the warnings in these sections. Installation, service and annual inspection of controller must be done by an electrician qualified in the installation and service of control systems for heating equipment. -
Page 12: Figure 1: Example Site Layout
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER NSTALLATION ANUAL FIGURE 1: Example Site Layout NOTE: Conceptual drawing, not to scale. Venting not shown. -
Page 13: Section 2: Specifications
SECTION 2: SPECIFICATIONS 2.1 ROBERTS GORDON ® ULTRAVAC™ Controller 2.1.1 Enclosure Standard Enclosure Construction: 16 gauge painted steel, hinged door, removable knockouts provided. Dimensions: 14.7" w x 17.7" h x 3.5" d NEMA 4 Enclosure (P/N 10080302) Description: NEMA 4 enclosure is sold separately as an option. -
Page 14: Figure 2: Roberts Gordon
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER FIGURE 2: ROBERTS GORDON 120 Vac Outputs Relay Board OUTPUT OUTPUT OUTPUT Plug-In Relays 24 V Input Connections 24 V Board 24 V Power Input Outputs RS 232 Control Direct Connect Board NC C NC C NC C NC C... -
Page 15: Variable Frequency Drive (Vfd)
2.3 Variable Frequency Drive (VFD) 2.3.1 Enclosure Standard Models Construction: 14 gauge painted steel, mounting panel included, left-hinged door, vented. Dimensions: 12" w x 14 3/8" h x 8" d Protection: UL 50 Type 1, NEMA Type 1 NEMA 4 Models Description: Drive assembly and components fully factory assembled inside NEMA 4... -
Page 16: Figure 3: Variable Frequency Drive Components (Factory Pre-Wiring Shown)
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER FIGURE 3: Variable Frequency Drive Components (Factory pre-wiring shown) Variable Frequency Drive (1 Ø input model shown) L2/N Terminal Inputs 460 V 3 Ø outputs 120 V signal from relay board NSTALLATION ANUAL 230 V 3 Ø or Relay 120 V output #8... -
Page 17: Section 3: Installation
SECTION 3: INSTALLATION WARNING Severe Injury Hazard Mount controls with materials with a minimum working load of 75 lbs (33 kg). Failure to follow these instructions can result in death, injury or property damage. Installation of the ROBERTS GORDON ULTRAVAC™ Controller and the associated external electrical wiring must be done by an electrician qualified in the installation of control systems for heating equipment. -
Page 18: Cable Requirements
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER 3.3 Cable Requirements: 3.3.1 Line Power Supply: As per individual building specification for class of cable to be used. Use copper conductors only. To size the cable, use the amperages of the burners given on Page 13, Section 3.4.1, for each individual zone. -
Page 19: Electrical Installation Requirements
3.4 Electrical Installation Requirements DANGER Electrical Shock Hazard Disconnect electrical before servicing. This appliance must be connected to a properly grounded electrical source. Replace cover before operating. Failure to follow these instructions can result in death or electrical shock. 3.4.1 The enclosure must be supplied from a local fused isolator rated for a total amperage not exceeding 25 A. -
Page 20: Indoor Sensor Placement
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER 3.7 Indoor Sensor Placement The sensor measures the air temperature in the building. It is important that the sensor is located in an area within the heated zone at occupant level. For the most accurate results, sensors should be mounted on an inside wall, away from any air vents or other sources of heat and cold. -
Page 21: Section 4: Typical External Diagrams
SECTION 4: TYPICAL EXTERNAL DIAGRAMS FIGURE 10: Central Controller Communication Equalization Wiring All ULTRAVAC™ Central Controllers are shipped with a communication equalization cable (P/N 10080450). The cable is supplied to equalize and balance the circuitry of the communications on the controller network that may be experiencing noise or transient voltage levels. Connect the communi- cation equalization cable as shown below to the first or the last controller on the data bus. -
Page 22: Figure 11: Roberts Gordon
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER FIGURE 11: ROBERTS GORDON Zone 1 Zone 2 Sensor Sensor (see NOTE 6) (see NOTE 6) Electrical wiring connections indicated by a dot; Ground Shield (one end only) indicated by; Separate line and low voltage circuits. Do not run line voltage wiring through bottom section of enclosure that houses the control board. - Page 23 ROBERTS GORDON ® ULTRAVAC™ Central Controller External Wiring (continued) Continued From Previous Page VFD Assembly ( 1 Ø input VFD model shown) L2/N Terminal 5 Terminal 2 Zone 3 Burners VFD Power Supply (1 Ø input VFD model shown, see NOTE 3) To Terminals M16/12.P M16/12.P...
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Page 24: Figure 12: Roberts Gordon
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER FIGURE 12: ROBERTS GORDON Zone 1 Zone 2 Sensor Sensor (see NOTE 6) (see NOTE 6) Electrical wiring connections indicated by a dot; Ground Shield (one end only) indicated by; Separate line and low voltage circuits. Do not run line voltage wiring through bottom section of enclosure that houses the control board. - Page 25 ® ROBERTS GORDON ULTRAVAC™ Satellite Controller External Wiring (continued) Continued From Previous Page VFD Assembly ( 1 Ø input VFD model shown) L2/N Terminal 5 Terminal 2 Zone 3 Burners VFD Power Supply (1 Ø input VFD model shown, see NOTE 3) To Terminals M16/12.P M16/12.P...
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Page 26: Section 5: Communications
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER SECTION 5: COMMUNICATIONS One ROBERTS GORDON ® ULTRAVAC™ Controller per building (called the "central controller) must have equipment for remote communications to a PC. This equipment consists of either a modem chip, an RS- 485 converter, or a TCP/IP communications module. -
Page 27: Rs-485 Converter For Central Controller
5.2 RS-485 Converter for Central Controller For remote on-site viewing of system status and settings of any controller, use the RS-485 converter to connect a single PC (9 pin serial port) to the RS- 485 terminals on the Central Controller. This will allow communication between one PC and any of the ULTRAVAC™... -
Page 28: Tcp/Ip Communication Module
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER 5.3 TCP/IP Communication Module For remote on-site viewing of system status and settings of any controller, use the TCP/IP communi- cation module to connect the controllers to a Local Area Network (LAN) via Ethernet cable. Any computer on the LAN that has ULTRAVAC™... -
Page 29: Figure 16: Tcp/Ip Communication Module Wiring
FIGURE 16: TCP/IP Communication Module Wiring Shrinkwrap RS-232 RS232 DIRECT AUX POWER Direct Port Dip Switch #1 set to ON UNIVERSAL INPUTS It is important that the module power wire is connected as shown (black=5 V- / red= 5 V+) wire orientation. Make sure to verify connection before connecting to the control board. -
Page 30: Direct Connect
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER 5.4 Direct Connect For local viewing of system status and settings of any controller, a portable PC can be connected. Using the 9 pin adapter provided, (See Page 24, Figure 17), you may wire from your computer serial port to the RS-232 direct connect port on the control board via standard 4-wire phone cable. -
Page 31: Communications Between Multiple Roberts Gordon
5.5 Communications Between Multiple ROBERTS GORDON If more than one ROBERTS GORDON VAC™ Controller is installed in a building, the controllers’ RS-485 communications must be wired in series. See Page 25, Figure 18. Connect the RS-485 terminal on controller 1 to the RS-485 terminal on controller 2 and so on in a daisy chain fashion. -
Page 32: Figure 19: Repeater Wiring
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER 5.5.1 Repeater If the RS-485 communications wire length is above 4000', a repeater must be used to extend the signal. The repeater can also be used to create parallel branches of ROBERTS GORDON communications bus wiring. Each repeater is sold in a 12" x 12" NEMA 1 enclosure with a 120/24 Vac transformer. -
Page 33: Section 6: Variable Frequency Drive Programming
SECTION 6: VARIABLE FREQUENCY DRIVE PROGRAMMING 6.1 VFD Parameter Settings For Use With ® ROBERTS GORDON ULTRAVAC™ The VFD parameters come with factory default set- tings. The following parameter settings must be changed for ROBERTS GORDON Settings can only be altered when the pump motor is stopped. -
Page 34: Altering Vfd Parameters
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER the password must be entered in order to access the parameters again. 6.2 Altering VFD Parameters Using the procedure described in Section 6.1.1 through Section 6.1.5, alter the following parameters: Parameter Parameter Factory Number Name Units Ending Password... -
Page 35: Section 7: Commissioning The Corayvac System
SECTION 7: COMMISSIONING THE CORAYVAC NOTE: The ROBERTS GORDON software must be installed on the PC, the communi- cation connection must be made to the controller and all wiring of the ROBERTS GORDON control boards, relay boards, burners, pumps and VFD must be completed before starting the commis- sioning procedure. -
Page 36: Figure 20: End Vent Vacuum
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER NSTALLATION ANUAL FIGURE 20: End Vent Vacuum... -
Page 37: Figure 21: Possible Damper Couplings' Locations
SECTION 7: C CORAYVAC ® OMMISSIONING YSTEM FIGURE 21: Possible Damper Couplings’ Locations... - Page 38 ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER Step 7.1.3 After setting end vent vacuums between 2.5" wc and 3.0" wc, while all the burners are still operating, use the down arrow button on the VFD to reduce the frequency of the output signal to the pump.
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Page 39: Section 8: Replacement Parts
SECTION 8: REPLACEMENT PARTS 8.1 ROBERTS GORDON ® ULTRAVAC™ Controller Replacement Parts Caution: Use only genuine ROBERTS GORDON Roberts-Gordon voids warranty. FIGURE 22: ROBERTS GORDON OUTPUT OUTPUT Plug-In NC C NC C NC C NC C NC C NC C NC C NC C Description... -
Page 40: Variable Frequency Drive Replacement Parts
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER Description Comms Equalization Cable (not shown, located only on Central Controller) Telephone Sharing Device, 4 port Relay 120 V Unitary Lights for 150 Style Control Board Lamp Green Enclosure Mount w/o Light Lamp Red Enclosure Mount w/o Light Light Diode 24 Vac 8.2 Variable Frequency Drive Replacement Parts Caution: Use only genuine ROBERTS GORDON... -
Page 41: Replacement Parts Instructions
Description Rotary Disconnect Handle (not shown) Rotary Disconnect Rod (not shown) 8.3 Replacement Parts Instructions DANGER Electrical Shock Hazard Disconnect electrical before servicing. This appliance must be connected to a properly grounded electrical source. Replace cover before operating. Failure to follow these instructions can result in death or electrical shock. -
Page 42: Roberts Gordon ® Ultravac™ Controller
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER NSTALLATION ANUAL 8.3.6 Variable Frequency Drive 25 A or 10 A Fuse To replace a fuse, turn off input power to the variable frequency drive assembly at the breaker or disconnect switch. Turn off 120 V power to the relay board inside the ROBERTS GORDON ®... -
Page 43: Section 9: Troubleshooting
SECTION 9: T ROUBLESHOOTING SECTION 9: TROUBLESHOOTING FIGURE 24: Troubleshooting Flow Chart... - Page 44 ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER NSTALLATION ANUAL Troubleshooting Flow Chart (continued)
- Page 45 SECTION 9: T ROUBLESHOOTING Troubleshooting Flow Chart (continued)
- Page 46 ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER NSTALLATION ANUAL Troubleshooting Flow Chart (continued)
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Page 47: Section 10: The Roberts Gordon
SECTION 10: THE ROBERTS GORDON ROBERTS-GORDON WILL PAY FOR: Within 42 months from date of shipment from Roberts- Gordon, replacement parts will be provided free of charge for any part of the controller which fails due to a manufacturing or material defect. Roberts-Gordon will require the part in question to be returned to the factory.